Five Ways to Improve Aluminum Die Casting Part Quality - 3ERP

Recognized for being incredibly lightweight and durable, aluminum is one of the most popular materials used in the production of functional parts and prototypes. It also offers impeccable corrosion resistance, thermal and electrical conductivity, and also retains dimensional stability even in high temperatures and harsh environments.

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Since this particular metal has such a high melting point, the optimal way to cast aluminum parts is by utilizing the aluminum die casting process. This metal casting process that forces molten metal into a mold cavity under high pressure. Aluminum die casting requires the use of a mold cavity, which is created using two hardened tool steel dies that are machined into a specific shape. With aluminum die casting, a cold-chamber machine is utilized.

Aluminum die casting reduces the amount of steps needed in production and prototyping, ultimately reducing manufacturing costs, while also providing parts with a high quality surface finish and exceptional dimensional consistency. This technique is especially advantageous in small-to-medium sized castings, and is widely used in industries such as automotive, aerospace, medical and more.

However, in order to optimize the part quality in the aluminum die casting process, there are a few critical factors that you should keep in mind. With these tips, you can utilize 3ERP’s professional-grade aluminum die casting services to its fullest potential, while also gaining a better understanding of this extremely popular manufacturing technique.

Understanding All Design Aspects and Geometric Features

Before a designer or engineer can utilize aluminum die casting to its full potential, it’s important that they first understand the design limitations and common geometric features that can be accomplished with this manufacturing technique. Here are some factors that you should keep in mind when designing a part for aluminum die casting.

• Draft – In aluminum die casting, the draft is considered as the amount of slope given to the cores or other parts of the die cavity, which makes it easier to eject the casting from the die. If your die cast is parallel to the opening direction of the die, the draft is a necessary addition to your casting design. If you optimize and implement a proper draft, it will be easier to remove the aluminum die casting from the die, increasing precision and resulting in higher quality surfaces.
• Fillet – The fillet is a curved juncture between two surfaces that can be added to your aluminum die casting to eliminate sharp edges and corners.
• Parting line – The parting line is the point where two different sides of your aluminum die casting mold comes together. The parting line location represents the side of the die that is used as the cover and which is used as the ejector.
• Bosses – When adding bosses to aluminum die casting, these will act as mounting points for parts that will need to be mounted later on. In order to optimize the integrity and strength of bosses, they should have the same wall thickness throughout the casting.
• Ribs – Adding ribs to your aluminum die casting will grant more support to designs that need maximum strength while still maintaining the same wall thickness.
• Holes – If you need to add holes or windows into your aluminum die casting mold, you’ll need to consider the fact that these features will grip to the die steel during the solidification process. To overcome this, designers should integrate generous drafts into hole and window features.

These are just the basics of what you should know when designing for aluminum die casting. If you want to optimize your mold further, you can contact 3ERP’s expert manufacturing team for assistance.

Understanding the Lifespan of Aluminum Die Casting Molds and Tooling

If you decide that aluminum die casting is the right option for your production needs, you should understand the lifespan and maintenance that aluminum die casting molds require. The life of the die is hard to pinpoint because it’s heavily dependant on a number of factors. You’ll want to keep a variety of aspects in mind, including the design of the part, the tool steel used for the die, the mold configuration, heat treatment, the aluminum alloy that is being utilized, the desired part quality and more.

Thankfully, when using 3ERP’s professional manufacturing service for aluminum die casting, our team will help ensure that each of these conditions is met accordingly.

Use Heat Treatment to Extend the Life of Aluminum Die Casting Mold

One of the best ways to extend the life of your aluminum die casting mold is by using heat treatment and die coatings. By applying these techniques, the heat checking will slow down immensely, ultimately extending the life of tooling. Of course, you’ll have to factor in that extra costs of these coatings, and decide whether it’s worth extending the lifespan of the aluminum die casting mold.

When it comes to heat treatment, there are a number of critically important aspects to consider, such as the heat treat furnace used, the number of temperings applied to the die blocks, as well as the quench rate used during the heat treatment processing. At 3ERP, we offer personalized aluminum die casting and heat treatment services that are best-suited for each customer, helping you achieve the perfect balance between affordability and part quality.

Selecting the Right Aluminum Alloy

It’s quite obvious that aluminum die casting molds are created with…well…aluminum. However, the aluminum alloy that is selected is a crucial part of this process. Each alloy type offers distinct mechanical advantages and disadvantages, and the right choice will be wholly dependent on what the function of your part will be. To help you get better acquainted with the available materials, here are a few of the most popular alloys used in aluminum die casting:

• Aluminum Alloy A380 – One of the most commonly used alloys for aluminum die casting, offering exceptional fluidity, pressure tightness and resistance to hot cracking.
• K-Alloy – This specialized material is a cold-chamber die cast alloy that is engineered for use in parts that must withstand harsh environments.
• Aluminum Alloy 383 – When your design is more complex, this alloy acts as a great alternative to A380 as it provides better corrosion resistance and is lightweight.
• Aluminum Alloy B390 – Compared to other available materials, this alloy has high hardness and excellent wear resistance.
• Aluminum Alloy A413 – This easily castable alloy is an ideal option for parts that require excellent pressure tightness, such as hydraulic cylinders.
• Aluminum Alloy DCA1 – This alloy is a perfect choice when you need to manufacture parts with high thermal and electrical conductivity, such as heatsinks.

Consult with Manufacturing Experts About Aluminum Die Casting

Last but certainly not least, if you’re interested in implementing aluminum die casting into your product development process, don’t be afraid to consult with the specialists working at a manufacturing and rapid prototyping service. For instance, at 3ERP, we have experts with knowledge on the best practices regarding aluminum die casting, helping to optimize your part design and quality once it’s finally produced.

Die casting is a very economical process for the large-scale production of metallic castings. With die casting, you can produce complicated shapes with high accuracy, thin wall thicknesses and smooth surfaces that require little finishing. Efficient die casting production starts with the part design. That's why there are die casting design tips you should follow.

Mould design

The first important die casting design note concerns the mould design. The mould must be able to withstand high pressure in the manufacturing process and allow smooth part production.

To do this, you should keep in mind during the design that the part can be easily removed from the mould without damage. Therefore, consider features such as parting lines at the beginning of your part design.

Fillets and radii

Fillets and radii are other important design features in die casting. They allow you to create smooth transitions between surfaces and avoid stress build-up. This affects the strength, durability and appearance of your parts.

Die casting design tips for fillets and radii:

• The size and shape of fillets and radii are application specific, but should not be smaller than 1mm.
• Larger radii are recommended for areas with higher loads.
• To prevent stress accumulation, avoid sharp corners and edges.
• Be aware of the radius when two surfaces meet, as these can affect the strength of the joint.
• Use fillets and radii throughout the design to maintain the strength and smoothness of the component.

Add draft angles aligned with the mould opening direction. This will ensure that your part can be removed from the mould without damage to the surface. Usually they range from 1 to 3 degrees, but can be greater for more complex parts.

Wall thickness

When designing the wall thickness, consider the desired stiffness, strength and weight of your product. The wall thickness affects the cooling time of the mould and the pressure that can be applied to the mould.

The wall thickness is application specific and depends for example on the mould size, the material used and the production processes.

Some minimum wall thicknesses for castings are:

• Magnesium: 1.016 - 2.54 mm
• Aluminium: 1.016 - 2.032 mm
• Zinc: 0.381 - 0.889 mm

Ribs and outside corners

You can use ribs to reinforce component walls and increase stiffness. They also allow you to distribute loads more evenly and thus prevent deformation. With outside corners you can create sharp transitions between surfaces.

The thickness of ribs and outside corners is also application-specific. For example, thicker ribs are important for components that are under heavy loads.

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Add ribs to the thinnest wall first so that this component does not become too thin. In addition, the spacing between ribs should be evenly distributed.

Another design tip: Avoid outside corners to prevent stress accumulation. If outside corners are necessary, their radius should be as large as possible to reduce stress.

Windows and holes

Windows and holes allow fluids to flow through or create a connection between two parts. You should consider them when designing your part so that they do not affect the strength and stability of the final product.

In most cases, windows are rectangular in shape and are located at the top or side of the mould. Holes, on the other hand, can take different shapes and lie anywhere in the mould.

Windows and holes should be rounded or fluted and located away from sharp corners and edges. In addition, windows and holes on the side of the mould may require demoulding bevels with larger angles.

Finished features

Some features are usually only possible after the castings have been cast. This finishing is an additional process step that increases production time and production costs.

If post-machining is necessary, follow these die casting design tips:

• Try to add as few reworked features as possible to keep costs comparatively low.
• Design the features to be as simple and accurate as possible.
• Choose the location of the features so that as little material as possible has to be removed.
• The tolerances of the features should be realistic and achievable.
• You can also add reworked features by inserting cores in the design phase. Cores create internal components in the casting by creating holes and other features in the final casting.

Parting lines

One feature that can be machined during finishing is the parting line. This is the line where the two halves of the mould meet. It is usually at the top or side of the part. The parting line is important in the design of the die cast part as it is where a visible seam will be created on the final product.

Make sure the parting line is where it is least visible. Also note the thickness of the line. This is because lines that are too thin can cause the part to break when it is removed, while parting lines that are too thick can cause uneven surfaces and imperfections in the final product.

Often there is also extra material that settles on the parting line. This extra material is called flash and can be removed during finishing.

Surface treatment grades

The final step in the casting process is the surface treatment. The type of treatment depends on the area of application of your end product.

It is divided into different grades:

Grade 1 (Utility Grade) - for basic use.

Grade 1 is also called Utility Grade. This surface after casting does not need any cosmetic treatment and this grade is best suited for castings with coatings.

Grade 2 (Functional Grade) - functional & simple

The 2nd grade is the Functional Grade. It is used for grinding and painting and therefore for castings with decorative coatings.

Grade 3 (Commercial Grade) - for commercial use

Grade 3, also called Commercial Grade, is suitable for electrostatically painted and custom surface treatment. It is mainly used for structural components that are used under high loads.

Grade 4 (Consumer Grade) - for end-user use.

As grade 4 is intended for consumer use, the surface does not have any disturbing defects. Therefore, this grade is suitable for decorative end products.

Grade 5 (Superior Grade) - for special quality requirements

The 5th grade has a micrometre-precise application of the coating. It is best suited when the end products are bearings for seals and gasket seats.

More die casting design tips with us

If you have any further questions about design tips, we will be happy to assist you with your die-casting production. assemblean offers you the complete die-casting process with its own foundry and a wide range of materials. Request your quote online or by and in consultation with you we will realise a manufacturable solution.